Method and apparatus for controlling topographical variation on a milled cross-section of a structure

ABSTRACT

An improved method of controlling topographical variations when milling a cross-section of a structure, which can be used to reduce topographical variation on a cross-section of a write-head in order to improve the accuracy of metrology applications. Topographical variation is reduced by using a protective layer that comprises a material having mill rates at higher incidence angles that closely approximate the mill rates of the structure at those higher incidence angles. Topographical variation can be intentionally introduced by using a protective layer that comprises a material having mill rates at higher incidence angles that do not closely approximate the mill rates of the structure at those higher incidence angles.

This application is a continuation of U.S. patent application Ser. No.10/716,181, filed on Nov. 18, 2003, which is hereby incorporated byreference.

TECHNICAL FIELD OF THE INVENTION

The present invention relates to charged particle beam milling and, inparticular, to a method of controlling topographical variation on across-section of a structure.

BACKGROUND AND SUMMARY OF THE INVENTION

Semiconductor manufacturing, such as the fabrication of integratedcircuits, typically entails the use of photolithography. A semiconductorsubstrate on which circuits are being formed, usually a silicon wafer,is coated with a material, such as a photoresist, that changessolubility when exposed to radiation. A lithography tool, such as a maskor reticle, positioned between the radiation source and thesemiconductor substrate casts a shadow to control which areas of thesubstrate are exposed to the radiation. After the exposure, thephotoresist is removed from either the exposed or the unexposed areas,leaving a patterned layer of photoresist on the wafer that protectsparts of the wafer during a subsequent etching or diffusion process.

The photolithography process allows multiple integrated circuit devicesor electromechanical devices, often referred to as “chips,” to be formedon each wafer. The wafer is then cut up into individual dies, eachincluding a single integrated circuit device or electromechanicaldevice. Ultimately, these dies are subjected to additional operationsand packaged into individual integrated circuit chips orelectromechanical devices.

A similar process is used to manufacture read write components for usein data storage drives. In a typical data storage drive, the data isstored on round, flat disks called platters, usually made of glass or analuminum alloy. Special electromagnetic read/write devices called headsare used to either record information onto the disk or read informationfrom it. The read/write heads transform electrical signals to magneticsignals, and magnetic signals back to electrical once again. Each bit ofdata to be stored is recorded onto the hard disk using a specialencoding method that translates zeros and ones into patterns of magneticflux reversals.

The portion of a write head that actually writes data on the disk isreferred to as the write element. This element is typically made up oftwo poles that are separated by a gap. These poles generate a magneticfield when they are excited by a coil magnetically coupled to the poles.When the write element is in proximity to the disk, a magnetic fieldgenerated by the poles sets the magnetic orientation in given locationson the disk. In this manner, data is written on the disk.

As the computer industry continues to demand higher capacity and fasterperformance from hard disks and tape drives, there is an increasingdemand for suppliers to increase the amount of data that can be storedon a given storage medium. This amount of data, referred to as arealdensity, is usually expressed as the number of bits of data per squareinch of storage media. One of the major factors that determines theareal density of a hard disk is the track density. This is a measure ofhow tightly the concentric tracks on the disk can be packed. Trackdensity is largely determined by the width of the tracks, which is inturn largely determined by the width of the write element. A large writeelement will affect a larger area on the surface of a platter than willa smaller write element. As a result, track width can be decreased (andtrack density increased) by making the poles of the write headphysically narrower, especially at the write tip, thereby concentratingthe magnetic field into a smaller area on the platter surface.

A large percentage of the write heads used today are thin-film heads, sonamed because of the way in which they are manufactured. During themanufacturing process, a substrate wafer is coated with one or morelayers of a very thin film of alloy material deposited in specificpatterns. Alternating layers of an insulating material are alsodeposited onto the substrate. Lithographic techniques similar to thoseused to manufacture semiconductor circuits are used to form thedeposited layers into a pole-tip assembly having the desired geometry.

During the manufacturing process, variations in exposure and focusrequire that the patterns developed by lithographic processes becontinually monitored or measured to determine if the dimensions of thepatterns are within acceptable ranges. The importance of suchmonitoring, often referred to as process control, increases considerablyas pattern sizes become smaller, especially as minimum feature sizesapproach the limits of resolution available by the lithographic process.Typically, for structures such as write heads, the width dimension isone of the smallest feature dimensions, and it is the width dimensionthat is conventionally monitored to assess performance of thelithographic process.

Monitoring of pattern features and measurement of its dimensions,commonly referred to as metrology, is often performed using a chargedparticle beam system, such as a focused ion beam system (FIB), inconjunction with a scanning electron microscope (SEM).

During a typical metrology process, a FIB system is used to expose thecross-section of a structure, such as a write head, so that thestructure width can be accurately measured. FIB systems are widely usedin microscopic-scale manufacturing operations because of their abilityto image, etch, mill, deposit, and analyze very small structures withgreat precision. FIB systems produce a narrow, focused beam of chargedparticles (hereinafter referred to as ions) that is typically scannedacross the surface of a work piece in a raster fashion, similar to acathode ray tube. In most commercial FIB systems, the ions used arepositively charged gallium ions (Ga⁺) extracted from liquid metal ionsources. The extracted ions are accelerated, collimated, and focusedonto a work piece by a series of apertures and electrostatic lenses. Theion beam can be used to remove material from the work piece surface orto deposit material onto the surface. When used to remove material,often referred to as milling, the heavy gallium ions in the focused ionbeam physically eject atoms or molecules from the surface by sputtering,that is, by a transfer of momentum from the incoming ions to the atomsat the surface.

Because FIB sputter-milling can cause significant damage to smallstructures, the structure surface is often coated with a protectivelayer of tungsten before milling begins. Such a layer can be depositedusing a gas that decomposes in the presence of the ion beam and depositsmaterial onto the surface. This process is commonly referred to asFIB-induced chemical vapor deposition (CVD). Typically the precursorgas, such as tungsten hexacarbonyl gas, is directed onto the work piecesurface, usually via a fine needle inserted near the position of the ionbeam. The gas is broken down into volatile and non-volatile componentsby the low energy electrons generated when the ion beam strikes thesurface. The non-volatile component, in this case the protectivetungsten coating, is deposited onto the surface, while the volatilecomponent is pumped away.

Once the cross-section is exposed, a scanning electron microscope can beused to measure the width of the structure. The scanning electronmicroscope (SEM) allows for the production of an image of greatermagnification and higher resolution than can be achieved by the bestoptical microscopes. An SEM produces a finely focused beam of electronswhich is scanned across the surface of a work piece, typically in araster pattern. The electrons that make up the electron beam are calledprimary electrons. When the electron beam is directed at the work piecesurface, the primary electrons collide with electrons in orbit aroundthe nuclei of the atoms present in the work piece causing the emissionof secondary electrons. Some of the primary electrons will also bereflected from the work piece surface. These higher energy electrons(>50 eV) are called backscattered electrons. Both types of electrons canbe detected by inserting an appropriate detector near the specimen. Thedetector produces a variable voltage output; the more secondary orbackscattered electrons it detects, the greater will be the voltagegenerated.

The analog signal produced by the detector is typically converted into adigital brightness value by a device known as an Analog to Digitalconverter. The voltage of the detector's output signal is measured foreach point in the scan (commonly referred to as a pixel) and assigned anumber from representing a digital brightness value for that pixel.Although the gray-level resolution (the number of shades of gray used inthe image) can be varied, typically 256 gray levels are used, so thateach point is assigned a value from 0 (black) to 255 (white) accordingto the intensity of the voltage. The value for each pixel is stored in amemory array and used to produce a multilevel gray image of the targetsurface in which the brightness of each point on the image is determinedby the number of secondary or backscattered electrons ejected while theprimary electron beam was impinging at that point. Areas where arelatively low number of electrons are emitted will appear darker in theimage, while areas where a relatively high number of electrons areemitted will appear brighter.

The average number of secondary electrons produced per primary electronis called the secondary-electron coefficient (SEEC), and is typically inthe range 0.1 to 10 (varying between different materials). The averagenumber of backscattered electrons reflected per primary electron iscalled the backscattered-electron emission coefficient (BEEC). Thenumber of electrons emitted at a given pixel depends on many factors,such as the topography of the sample, the curvature of the targetsurface, the electron emission coefficient of the target material, andeven (especially for backscattered electrons) the atomic number of theelements present in the sample. Because different materials may havesignificantly different electron emission coefficient values, the yieldof emitted electrons, whether secondary or backscattered detection isemployed, may be used as a contrast mechanism to distinguish betweendifferent materials on a surface—especially where the difference betweenthe electron emission coefficients of the two materials is relativelyhigh.

Typically, to measure the width of cross-section of a structure, the SEMis used in conjunction with automatic metrology software. As theelectron beam is scanned across the exposed cross-section, whethersecondary or backscattered detection is employed, there will typicallybe a change in electron intensity at the edges of the structure. Thischange can be due to a change to topography or to a transition betweentwo different materials. An algorithm is used to assign an edge positionbased upon the contrast at the edges of the structure and to determinethe distance between those edges. Thus, the accuracy of the algorithm'sedge position determination determines the accuracy of the widthmeasurement.

Unfortunately, there are a number of problems when the above-describedprocesses are used to monitor the width of very small structures such asmodern write-head poles. SEM image based metrology relies upon theability to make measurements between gray level transitions. Gray levelvariations in an SEM image can either result from changes in topographyor from material differences. For structures such as the write headsdiscussed above (which are covered with a protective overcoat prior toFIB cross-sectioning) the edges that must be detected and measured areformed solely by material differences between the pole structure and itsovercoat material. In order to accurately measure the distance betweentwo such material boundaries, it is desirable to reduce or eliminate anyvariation in topography so that measurements are based entirely upon thedifference in material.

When a FIB system is used to mill a cross section of a selectedstructure of interest which has been coated with a protective layer of asecond material, a phenomenon known as “curtaining” often affects theaccuracy of any subsequent SEM measurement. FIG. 1A is a SEM micrographof a cross-section of a typical NiFe write-head with a tungstenovercoat. Write-head 150 is composed of a compound known as Permalloy—an81/19 alloy of nickel and iron. Overcoat 140 is composed of tungstendeposited to protect the write-head during FIB milling and to providethe necessary gray level difference for edge-finding and widthmeasurement of the pole. As illustrated by FIG. 1A, the edges of thewrite-head in areas 120 and 130 are not well defined because artifactsfrom the milling process associated with using tungsten as the overcoatmaterial partially obscure the material boundaries. This is commonlyreferred to as curtaining.

FIG. 1B is a SEM micrograph of the same cross-section observed from aslight angle with respect to the vertical face of the cross-section. Ascan be seen in area 132, the Permalloy write-head 150 is actuallyrecessed slightly with respect to the tungsten layer 140. During ionbeam milling, sputtered material can redeposit on the workpiece surface.A recess, as shown in FIG. 1B, tends to collect redeposited materialduring the milling process. The resulting variation in topographyresults in gray level variations in an SEM image that partially obscuresthe boundary or edge between the Permalloy write-head and the tungstenovercoat layer. The poorly defined transition between the Permalloy andthe tungsten results in the curtaining effect discussed above.Curtaining can make edge recognition difficult and can possibly lead toa less accurate cross-section measurement by automated metrologysoftware.

One approach to the problem of curtaining is the use of a tilted ionbeam to mill the cross-section. The workpiece is then rotated 90degrees, and the ion beam is used to remove some of the redepositedmaterial. This approach, however, suffers from a number of shortcomings.First, because the cross-section is milled at an angle, the actualvertical cross-section measure must be calculated from the angledmeasurement. The resulting width determination is less accurate than ifthe vertical cross-section were to be measured directly. Further, theprocess takes significant additional time because the cross-section mustbe milled, the sample rotated, and then the redeposited material must beremoved before an SEM image can be taken and measurements can beperformed. Any increase in time required to complete a criticaldimension measurement process is very undesirable for any in-lineprocess control.

Thus, there is still a need for an improved method of controllingtopographical variations when milling a cross-section of a structuresuch as a write head pole. A reduction in topographical variation willproduce a more planar cross-section face and accordingly can improve theaccuracy of metrology applications such as measuring a width of thecross-section of such a structure.

SUMMARY OF THE INVENTION

It is an object of the invention, therefore, is to allow improvedcontrol over topographical variations when milling a cross-section of astructure, such as reducing topographical variation on a cross-sectionof a write-head in order to improve the accuracy of metrologyapplications. A preferred embodiment of the invention described andclaimed herein comprises the use of a protective layer deposited overthe structure, followed by ion milling to expose the cross-section ofthe structure, and SEM metrology to determine dimensions such as thewidth of the structure. In a preferred embodiment of the invention,topographical variation is reduced by using a protective layer whichcomprises a material having mill rates at higher incidence angles (up to90 degrees) that closely approximates the mill rates of the structure atthose higher incidence angles. In another preferred embodiment of theinvention, a protective layer of carbon is deposited over a structurecomposed of Permalloy to allow for improved metrology of the Permalloystructure. In still another preferred embodiment of the invention,topographical variation can be intentionally introduced by using aprotective layer that comprises a material having mill rates at higherincidence angles that do not closely approximate the mill rates of thestructure at those higher incidence angles.

The foregoing has outlined rather broadly the features and technicaladvantages of the present invention in order that the detaileddescription of the invention that follows may be better understood.Additional features and advantages of the invention will be describedhereinafter. It should be appreciated by those skilled in the art thatthe conception and specific embodiments disclosed may be readilyutilized as a basis for modifying or designing other structures forcarrying out the same purposes of the present invention. It should alsobe realized by those skilled in the art that such equivalentconstructions do not depart from the spirit and scope of the inventionas set forth in the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of the present invention, and theadvantages thereof, reference is now made to the following descriptionstaken in conjunction with the accompanying drawings, in which:

FIG. 1A is a SEM micrograph of a cross-section of a typical prior artPermalloy write-head with a tungsten overcoat.

FIG. 1B is a SEM micrograph of the cross-section of FIG. 1A observedfrom a slight angle with respect to the cross-section face.

FIG. 2 shows a typical prior art dual beam FIB/SEM system.

FIG. 3 shows the different ion beam incidence angles that can result asa cross-section is exposed during a milling process.

FIG. 4 is a graph showing mill rate versus beam incidence angle forvarious materials.

FIG. 5 is a SEM micrograph of a cross-section of a Permalloy write-headwith a carbon overcoat according to the present invention.

FIG. 6 is a flowchart showing the steps in determining the width of astructure composed of Permalloy according to the present invention.

FIG. 7 is a flowchart showing the steps of selecting a suitable overcoatmaterial according to a preferred embodiment of the present invention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

Preferred embodiments of the present invention are directed to methodsand an apparatus for controlling topographic features or variations on amilled cross-section of a structure. The topographic features that canresult from milling the cross-section can be reduced or even eliminatedby careful matching of the substrate (the material that the feature iscomposed of) with a protective overcoat material. Specifically, anappropriate overcoat material according to the invention will have amill rate at higher incidence angles (up to 90 degrees) that closelyapproximates the mill rate of the substrate material at those higherincidence angles at which the milling cross section is formed. Preferredembodiments of the present invention can thus be used to produce across-section face that is almost perfectly planar. This allows for SEMmetrology based entirely upon material differences rather thanvariations in topography, which is desirable for metrology on astructure. In contrast, topographical variations can be intentionallyintroduced by choosing an overcoat material having a dissimilar millrate at higher incidence angles than the mill rate of the substrate atthose higher incidence angles.

Although much of the following description is directed toward themeasurement of the width of a structure, the methods of the presentinvention are equally applicable to any application where chargedparticle beam milling is used to expose a cross-section of a smallstructure of a first material which has been coated with a layer of asecond material. Further, although much of the following description isalso directed toward the use of focused ion beams to mill thecross-section and electron beams to image and measure the cross-section,the methods of the present invention could equally be utilized withother milling and imaging techniques including other types of chargedparticle beam systems, electron beam milling, or optical processing.Hence, the scope of the present invention should not be limited to thespecific embodiments discussed herein.

FIG. 2 shows a typical dual beam FIB/SEM system 20 used to implement oneaspect of the present invention. Focused ion beam system 200 includes anevacuated envelope 211 having an upper neck portion 212 within which arelocated an ion source 214 and a focusing column 216 including extractorelectrodes and an electrostatic optical system. Ion beam 218 passes fromion source 214 through column 216 and between electrostatic deflectionmeans schematically indicated at 220 toward sample 222, which comprises,for example, a semiconductor device positioned on movable X-Y stage 224within lower chamber 226. An ion pump 228 is employed for evacuatingneck portion 212. The chamber 226 is evacuated with turbomolecular andmechanical pumping system 230 under the control of vacuum controller232. The vacuum system provides within chamber 226 a vacuum of betweenapproximately 1×10⁻⁷ Torr and 5×10⁻⁴ Torr. If an etch assisting, an etchretarding gas, or a deposition precursor gas is used, the chamberbackground pressure may rise, typically to about 1×10⁻⁵ Torr.

High voltage power supply 234 is connected to ion source 214 as well asto appropriate electrodes in focusing column 216 for forming an ion beam218 and directing the same downwardly. Deflection controller andamplifier 236, operated in accordance with a prescribed pattern providedby pattern generator 238, is coupled to deflection plates 220 wherebybeam 218 may be controlled to trace out a corresponding pattern on theupper surface of sample 222. In some systems the deflection plates areplaced before the final lens, as is well known in the art.

The ion source 214 typically provides a metal ion beam of gallium,although other ion sources, such as a multicusp or other plasma ionsource, can be used. The ion source 214 typically is capable of beingfocused into a sub one-tenth micron wide beam at sample 222 for eithermodifying the sample 222 by ion milling, enhanced etch, materialdeposition, or for the purpose of imaging the sample 222. A chargedparticle multiplier 240 used for detecting secondary ion or electronemission for imaging is connected to amplifier 242. The amplifiedsignals are converted into digital signals and subjected to signalprocessing by the signal processor unit 243. The resulting digitalsignal is to display an image of workpiece 222 on the monitor 244.

A scanning electron microscope 241, along with power supply and controlunit 245, is also provided with the FIB system 200. An electron beam 250is emitted from a cathode 252 by applying voltage between cathode 252and an anode 254. Electron beam 250 is focused to a fine spot by meansof a condensing lens 256 and an objective lens 258. Electron beam 250 isscanned two-dimensionally on the specimen by means of a deflection coil260. Operation of condensing lens 256, objective lens 258, anddeflection coil 260 is controlled by power supply and control unit 245.

Electron beam 250 can be focused onto workpiece 222, which is on movableX-Y stage 224 within lower chamber 226. When the electrons in theelectron beam strike workpiece 222, secondary electrons are emitted.These secondary electrons are detected by secondary electron detector240 or by backscattered electron detector 262, which are connected to anamplifier 242. The amplified signals are converted into digital signalsand subjected to signal processing by the signal processor unit 243. Theresulting digital signal is to display an image of workpiece 222 on themonitor 244.

A gas delivery system 246 extends into lower chamber 226 for introducingand directing a gaseous vapor toward sample 22. U.S. Pat. No. 5,851,413to Casella et al. for “Gas Delivery Systems For Particle BeamProcessing,” assigned to the assignee of the present invention,describes a suitable fluid delivery system 246. Another gas deliverysystem is described in U.S. Pat. No. 5,435,850 to Rasmussen for a “GasInjection System,” also assigned to the assignee of the presentinvention.

A door 270 is opened for inserting sample 222 onto stage 224, which maybe heated or cooled, and also for servicing an internal gas supplyreservoir, if one is used. The door is interlocked so that it cannot beopened if the system is under vacuum. The high voltage power supplyprovides an appropriate acceleration voltage to electrodes in ion beamcolumn 216 for energizing and focusing ion beam 218. Dual beam FIB/SEMsystems are commercially available, for example, from FEI Company,Hillsboro, Oregon, the assignee of the present application.

FIB system 200 is first used to apply a protective layer to a structureof interest on workpiece 222, such as a permalloy write head on amagnetic recording head wafer, typically composed of a material such asAluminum Titanium Carbide (AlTiC). The protective layer is deposited,for example, using an appropriate gas delivered by gas delivery system246 via a fine needle inserted near the position of the ion beam. Thegas decomposes in the presence of the ion beam and deposits materialonto the surface. For example, naphthalene gas can be used to deposit aprotective layer of carbon.

FIB system 200 then directs an ion beam 218 toward the structure ofinterest in order to expose the cross-section of the structure so thatthe structure width can be accurately measured. A typical system mightuse a beam current of 1 nA, a beam energy of 30 keV, a beam diameter of5 nm to 50 nm, and a dwell point spacing of 2 to 200 nm. Skilled personscan readily determine appropriate beam characteristics to suit aparticular application. Once the cross-section is exposed, scanningelectron microscope 41 can be used to measure the width of thestructure.

Scanning electron microscope 241 produces a finely focused electron beam250, which is scanned across the surface of the structure, preferably ina raster pattern. When the electrons in the electron beam 250 strike thesurface of work piece 222, secondary electrons and backscatteredelectrons are emitted. Respectively, these electrons are detected bysecondary electron detector 240 or backscattered electron detector 262.The analog signal produced either by secondary electron detector 240 orbackscattered electron detector 262 is amplified by amplifier 242 andconverted into a digital brightness value by signal processor unit 243.As the electron beam 250 is scanned across the exposed cross-section,there will be a change in emitted electron intensity at the edges of thestructure. An algorithm is used to assign an edge position based uponthe difference in brightness values or contrast at either of the edgesof the structure and to determine the distance between those edges. Atypical system might use an electron beam current of 10 to 100 pA, abeam energy of 1 keV, and an electron beam current density of 2000 A/cm²A typical system might also use an electron beam spot size of 2 to 5 nm,a refresh period of approximately 0.5 to 5 seconds, and a scanning fieldwidth of 0.5 to 5.0 microns. Again, skilled persons can readilydetermine appropriate beam characteristics to suit a particularapplication.

When using the FIB system shown in FIG. 2 to mill a cross-section of astructure of interest, the etch rate of the ion milling is very muchdependent upon the incidence angle. The incidence angle of an ion beamis defined as the angle of the beam with respect to a normal to thetarget surface. Milling rate (also referred to as sputter rate)typically increases with the beam angle of incidence up to a certainangle, then decreases. Although most materials follow this general rule,the exact milling rate at a given incidence angle, along with theincidence angle resulting in the highest milling rate, will vary frommaterial to material. For example, the milling rate for tungstenincreases with beam angle of incidence until the beam angle is around75°, then it decreases.

During the process of using a FIB to mill a cross-section, the ion beamwill have a different incidence angle at different locations on theworkpiece surface at different stages in the milling process. FIG. 3illustrates the different angles that can result during the millingprocess. As the ion beam is directed at points 301 through 304, thecorresponding angle of incidence will be θ₁ for point 301, θ₂ for point302, θ₃ for point 303, and θ₄ for point 304. As shown by FIG. 3, thesurface of the workpiece at point 304 is nearly perpendicular to the ionbeam, and the resulting incidence angle (θ₄) is relatively small. As theion beam moves to successive points 303, 302, and 301, the incidenceangles become larger. For point 301, located where the workpiece surfacehas been milled to produce the final, nearly vertical wall of the crosssection, the incidence angle can approach 90 degrees. The cross-sectionface is formed mainly through FIB milling at high incidence angles.Skilled persons will recognize that the incidence angle that forms across-section face might vary depending on milling conditions.

Where the surface cross-section being milled is composed of twodifferent materials, such as a permalloy write-head with a tungstenovercoat, the two materials will not only have different milling rates,the difference in milling rate will vary at different incidence angles.

FIG. 4 shows the relationship between mill rate (sputter yield) and beamincidence angle for tungsten, NiFe (permalloy), and carbon. The valueswere calculated using a Monte Carlo simulation program. As shown by thegraph, the mill rate of tungsten is higher than the mill rate of NiFe atan incidence angle smaller than 60 degrees. Above 60 degrees, however,NiFe will mill faster than tungsten. The difference is particularlypronounced when the beam incidence angle is around 75 degrees.

Applicants believe that this difference in milling rate results in thecurtaining effect described above. Referring again to FIG. 1A and FIG.1B, the higher milling rate of Permalloy at higher incidence angles(greater than 75 degrees up to an angle approaching 90 degrees) ascompared to tungsten will result in faster milling of the Permalloysidewalls. As a result, the vertical surface of the Permalloy write-headwill be recessed with respect to the slower milling tungsten layer. Thisrecess tends to collect sputtered material at the permalloy-tungsteninterface, which in turn results in a poorly defined transition betweenthe Permalloy and the tungsten.

This recess, along with the curtaining effect it causes, is atopographical artifact associated with the selection of the overcoatmaterial (tungsten) and the process of producing the cross section.Topographical variations, resulting both from the recess and thecollection of sputtered material, introduce gray level variations in theimage that compete with the more relevant contrast mechanism based onmaterial differences. These gray level variations can make edgerecognition difficult and can possibly lead to a less accuratecross-section measurement by automated metrology software.

The mill rate of carbon, however, is slightly higher than the mill rateof NiFe at higher incidence angles. Therefore, it can be predicted thatmilling a cross-section of a Permalloy structure with a carbon overcoatwill not result in a Permalloy recess or the resulting curtaining seenwith tungsten. FIG. 5 is a SEM micrograph of a cross-section of aPermalloy write-head 550 with a carbon overcoat 540. As illustrated byFIG. 5, the edges of the write-head 550 in areas 520 and 530 are quitewell defined and exhibit none of the curtaining observed in FIG. 1A.

By matching the mill rate of the overcoat material and the underlyingstructures, topographical variations resulting from milling thecross-section are minimized to a point where they will not affect themetrology. The resulting measurements are more precise and more robustto process variations. Typically, the closer the milling rates can bematched at the higher incidence angles which actually form thecross-section face, the more topographical variations resulting from themilling process will be reduced.

For a typical milling process, the cross-section face will be formed atincidence angles from around 75 degrees up to 90 degrees. As a result,matching the mill rates for this range of incidence angles is preferred.However, skilled persons will recognize that variations in millingconditions, for example variation in mill pattern or ion beam dose, cansometimes result in a cross-section forming at a different incidenceangle. Applicants believe that matching milling rates through a largerrange of high incidence angles (from around 45 degrees up to 90 degrees)would allow topographical variations to be controlled for a much widerrange of milling conditions. Due to the limited number of availableovercoat materials, however, it may not always be possible to match millrates through a larger range of higher incidence angles. For mostmetrology applications using typical milling conditions, it will bepreferable to match mill rates at incidence angles higher than 75degrees. In most cases, this will not only allow for a significantreduction in topographical variation over the prior art, but will alsoresult in a number of acceptable overcoat materials—which in turn willallow factors such as electron emission contrast (discussed below) orease of overcoat application to be taken into consideration.

Carbon also has the advantage of providing a better electron emissioncontrast with NiFe than does tungsten. As discussed above, the yield ofemitted electrons may be used as a contrast mechanism to distinguishbetween different materials on a surface. A greater relative differencebetween the emitted electron coefficients of two materials allows formore accurate edge determination.

For example, the backscattered electron emission coefficient for Ni/Fe(with a 2 keV beam energy) is approximately 0.2 to 0.3, while thebackscattered electron emission coefficient for tungsten isapproximately 0.4. The BEEC for tungsten thus differs from the BEEC forPermalloy by a factor of about 1.6. Carbon, on the other hand, has abackscattered electron emission coefficient of approximately 0.07. TheBEEC for carbon differs from the BEEC for Permalloy by a factor of about3.6. As a result, the contrast between carbon and Permalloy is muchgreater than the contrast between tungsten and Permalloy. This greatercontrast can allow a more accurate edge determination and thus a moreaccurate measurement of the width of the cross-section.

In accordance with the present invention, the use of carbon rather thantungsten as an overcoat material will greatly enhance the accuracy ofthe determination of the width of a structure composed of Permalloy.FIG. 6 is a flowchart showing the steps in determining the width of astructure composed of Permalloy according to the present invention.

In step 601, the workpiece is loaded into an FIB/SEM system such as theone illustrated in FIG. 2 by mounting the workpiece on the FIB/SEMstage. The workpiece can be loaded manually or automatically, forexample by an automatic handler system.

In step 602, the workpiece is aligned. This alignment can also beaccomplished manually, for example by an operator using an opticalmicroscope, or automatically, for example by using an automatic handlerrobot which locates a notch or flat edge of the workpiece in order todetermine the proper orientation.

In step 604, the stage is positioned so that the structure of interestis within the area scanned by the charged particle beam. Thispositioning can be accomplished, for example, by storing and usingpositional coordinates.

In step 610, structure of interest is coated with a protective layer ofcarbon by way of a gas that decomposes in the presence of the ion beamand deposits material onto the surface. A precursor gas, such asnaphthalene gas, is directed onto the workpiece surface. The gas isbroken down by the ion beam into volatile and non-volatilecomponents—the non-volatile component, in this case a protective carboncoating, is deposited onto the surface, while the volatile component ispumped away.

In step 620, the FIB system is used to expose the cross-section of thestructure of interest, such as a Permalloy write head, by millingthrough the protective layer and the structure of interest.

Once the cross-section is exposed, in step 630, a scanning electronmicroscope is used to measure the width of the structure through the useof an algorithm that determines the location of two edges of thestructure of interest. As the SEM beam is scanned across the exposedcross-section, the algorithm is used to assign an edge position basedupon the contrast at the edges of the structure and to determine thedistance between those edges.

According to the present invention, the same general steps can befollowed to determine the width of a structure composed of a materialother than Permalloy provided that an appropriate overcoat material issubstituted for the carbon layer. Applicants have discovered thatmatching the milling rate of the protective layer and the structurebeing measured at higher incidence angles (greater than 75 degrees up toan angle approaching 90 degrees) reduces curtaining. Where theprotective coating mills at about the same rate as the structure,topographical artifacts that can collect redeposited particles areminimized. The lack of topographical variation in the milled crosssection results in a more defined edge between the two materials and, asa result, more accurate determination of the structure's width by an SEMand automated metrology software.

Preferably, an appropriate overcoat material will have a mill rate athigher incidence angles that closely approximates the mill rate of thestructure material. Most preferably, an appropriate overcoat materialwill have a mill rate at higher incidence angles that is equal to orslightly higher than the mill rate of the structure material. Skilledpersons will realize that an overcoat material with a slightly lowermill rate than the structure at higher incidence angles might provideacceptable results, but there would likely be some degree of curtaining.As discussed above, where possible, it is desirable for the mill ratesof overcoat and substrate to match throughout a broader range of higherincidence angles (for example from 45 degrees approaching 90 degrees) inorder to account for variations in milling conditions.

FIG. 7 is a flowchart showing the steps of selecting a suitable overcoatmaterial in order to control topographical variation in a milledcross-section according to a preferred embodiment of the presentinvention.

In step 702, the mill rate at incidence angles greater than 75 degreesfor the material making up the structure of interest is determined. Thismill rate can be determined, for example, experimentally. Known millrates at specific incidence angles can also be found in literature, orby performing calculations using one of the commercially availablesimulation software packages. For some applications, it might bedesirable to determine mill rates at incidence angles above 45 degrees.

In step 704, a preliminary group of acceptable overcoat materials isidentified by using reference values for mill rates throughout thedesired range of incidence angles. As discussed above, in order toreduce topographical variation, an appropriate overcoat material willhave mill rate throughout the desired range of incidence angles thatclosely approximates the mill rate of the structure material over thatsame range of incidence angles.

In optional step 706, the milling rates of acceptable overcoat materialsfound in known references can be verified experimentally.

In step 708, the appropriate electron emission coefficient (EEC) for thestructure material is determined (depending upon the type of electrondetection employed). The electron emission coefficient can bedetermined, for example, experimentally. Known electron emissioncoefficient values for different materials can also be found inliterature.

In step 710, the EEC for the preliminary group of acceptable overcoatmaterials is determined. The EEC for this group of materials can also bedetermined, for example, experimentally or by using known EEC values fordifferent materials as found in literature.

In step 712, an appropriate overcoat material is determined from thepreliminary group of acceptable overcoat materials by selecting theacceptable material with the greatest relative difference in EEC ascompared to the structure material. Skilled persons will recognize thatin some circumstances, it might be desirable to choose an overcoat otherthan the material with the greatest relative difference in EEC. Forexample, where the overcoat material with the greatest relativedifference in EEC is very expensive or difficult to use, it might bepreferable to use a material with a lower difference in EEC. In suchcases, skilled persons will recognize that a greater difference in EECis more desirable, but must be balanced against other factors.

In optional step 714, the performance of a selected overcoat materialcan be verified experimentally as discussed above.

Once an acceptable material is selected, the process as described abovecan be implemented to produce a cross-section with well-defined edges.The selected material can be deposited over the structure as aprotective layer, followed by ion milling to expose the cross-section ofthe structure, and SEM metrology to determine the width of thestructure. The present invention thus allows for improved metrology of across-section of a structure and thus more effective process control.

Although much of the previous description is directed toward themeasurement of the width of a structure, the methods of the presentinvention are equally applicable to any application where chargedparticle beam milling is used to expose a cross-section of a smallstructure of a first material which has been coated with either aprotective or functional layer of a second material. For example, themethods described above could be used to produce a more planar face whenusing FIB milling to manufacture structures such as micro-minors for usein optical switch arrays for telecommunications, large screen displaysfor projectors, or even as part of a channel for planar laser devices.In such an application, improved flatness of the minor face would bevery desirable.

Further, skilled persons will recognize that the method described abovecould also be applied to produce a non-flat cross-section surface. If,for example, it is desirable to produce a recessed cross-section face,an appropriate overcoat material according to the invention would have amill rate at high incidence angles that is lower than the mill rate ofthe substrate at high incidence angles. During ion beam milling, thesubstrate material would mill faster than the overcoat material,resulting in a recessed substrate face.

Although the present invention and its advantages have been described indetail, it should be understood that various changes, substitutions andalterations can be made to the embodiments described herein withoutdeparting from the spirit and scope of the invention as defined by theappended claims. Moreover, the scope of the present application is notintended to be limited to the particular embodiments of the process,machine, manufacture, composition of matter, means, methods and stepsdescribed in the specification. As one of ordinary skill in the art willreadily appreciate from the disclosure of the present invention,processes, machines, manufacture, compositions of matter, means,methods, or steps, presently existing or later to be developed thatperform substantially the same function or achieve substantially thesame result as the corresponding embodiments described herein may beutilized according to the present invention. Accordingly, the appendedclaims are intended to include within their scope such processes,machines, manufacture, compositions of matter, means, methods, or steps.

1-41. (canceled)
 42. An apparatus for exposing a planar cross-section ofa structure composed of a first material, the apparatus comprising: afocused ion beam system and gas delivery system for depositing a layerof a second material on said structure; a gas source of said secondmaterial, said second material having mill rates at higher incidenceangles that match the mill rates of the first material at thoseincidence angles; and wherein the ion beam system is used also formilling the structure in order to expose a cross-section of thestructure thereby producing a uniformly planar face on said exposedcross-section.
 43. The apparatus of claim 42 in which said secondmaterial has mill rates at incidence angles greater than 45 degrees thatmatch the mill rates of the first material at incidence angles greaterthan 45 degrees.
 44. The apparatus of claim 43 in which said secondmaterial has mill rates at incidence angles greater than 45 degrees thatthat are equal to or greater than the mill rates of the first materialat incidence angles greater than 45 degrees.
 45. An apparatus formeasuring a dimension of a cross-section of a structure composed of afirst material, the apparatus comprising: an ion beam system and gasdelivery system for depositing a layer of a second material on saidstructure; said second material having mill rates at higher incidenceangles that match the mill rates of the first material at thoseincidence angles; wherein the ion beam system is also used for directingan ion beam at the structure in order to expose a planar cross-sectionof the structure and said layer of the second material; an electron beamsystem for directing an electron beam at the planar cross section; and acomputer programmed for determining the width of the structure from thecross section based on the distance between two or more edges of thestructure, the distance determined by assigning an edge position ateither of the edges of the structure, the edge position based upon abrightness or contrast value assigned to either of the edges.
 46. Theapparatus of claim 45 in which said second material has mill rates atincidence angles greater than 45 degrees that are equal to or greaterthan the mill rates of the first material at incidence angles greaterthan 45 degrees.
 47. The apparatus of claim 42 in which said secondmaterial has mill rates at incidence angles greater than 45 degrees thatmatches the mill rates of the first material at incidence angles greaterthan 45 degrees.
 48. The apparatus of claim 47 in which said secondmaterial has mill rates at incidence angles greater than 45 degrees thatare equal to or greater than the mill rates of the first material atincidence angles greater than 45 degrees.
 49. The apparatus of claim 42in which said first material comprises an alloy of Ni and Fe.
 50. Theapparatus of claim 42 in which said second material is carbon.
 51. Theapparatus of claim 42 in which directing an ion beam at the structure inorder to expose a planar cross-section of the structure and said layerof a second material, comprises focused ion beam milling.
 52. Theapparatus of claim 42 in which determining the edge positions oncross-section comprises forming an image of said cross-section on animage forming device and applying an algorithm to assign an edgeposition based upon gray-level variations.
 53. The apparatus of claim42, wherein the computer is further programmed to chose the secondmaterial to be deposited as a protective layer on the structure composedof the first material prior to milling in order to control topologicalvariation of the cross-section of said structure, by: determiningwhether a planar or non-planar cross-section topography is desired;determining the approximate mill rate of the first material at higherincidence angles; if a planar cross-section is desired, selecting asecond material from known materials having a mill rate at higherincidence angles that match the mill rates of the first material atthose incidence angles; and if a non-planar cross-section is desired,selecting a second material from known materials having a mill rate athigher incidence angles that does not match the mill rates of the firstmaterial at those incidence angles.
 54. The apparatus of claim 53 inwhich a planar cross-section is desired and in which selecting a secondmaterial from known materials comprises selecting a second materialhaving mill rates at incidence angles greater than 45 degrees that matchthe mill rates of the first material at incidence angles greater than 45degrees.
 55. The apparatus of claim 54 in which selecting a secondmaterial from known materials comprises selecting a second materialhaving mill rates at incidence angles greater than 45 degrees that areequal to or greater than the mill rates of said first material atincidence angles greater than 45 degrees.
 56. The apparatus of claim 53in which selecting a second material from known materials comprises:selecting a preliminary group of materials from known materials withmill rates at higher incidence angles that match the mill rates of saidfirst material at higher incidence angles; determining the electronemission coefficient of said first material; determining the electronemission coefficient of each selected preliminary material; andselecting from said preliminary group, an appropriate second materialhaving the greatest relative difference in electron emission coefficientas compared to said first material.
 57. The apparatus of claim 56 inwhich selecting a second material from known materials comprisesselecting a second material having mill rates at incidence anglesgreater than 45 degrees that match the mill rates of the first materialat incidence angles greater than 45 degrees.
 58. The apparatus of claim53 in which a non-planar cross-section is desired and in which selectinga second material from known materials comprises selecting a secondmaterial having mill rates at incidence angles greater than 45 degreesthat do not match the mill rates of the first material at incidenceangles greater than 45 degrees.
 59. The apparatus of claim 58 in whichthe desired cross-section topography comprises a recessed cross-sectionface.
 60. The apparatus of claim 59 in which selecting a second materialfrom known materials comprises selecting a second material having millrates at incidence angles greater than 45 degrees that are that aresubstantially lower than the mill rates of said first material atincidence angles greater than 45 degrees.
 61. An apparatus for exposinga planar cross-section of a structure composed of a first material, theapparatus comprising: a focused ion beam system and gas delivery systemfor depositing a layer of a second material on said structure; acomputer programmed to chose the second material to be deposited as aprotective layer on the structure composed of the first material priorto milling in order to control topological variation of thecross-section of said structure, by: determining whether a planar ornon-planar cross-section topography is desired; determining theapproximate mill rate of the first material at higher incidence angles;if a planar cross-section is desired, selecting a second material fromknown materials having a mill rate at higher incidence angles that matchthe mill rates of the first material at those incidence angles; and if anon-planar cross-section is desired, selecting a second material fromknown materials having a mill rate at higher incidence angles that doesnot match the mill rates of the first material at those incidenceangles.
 62. The apparatus of claim 61 in which a planar cross-section isdesired and in which selecting a second material from known materialscomprises selecting a second material having mill rates at incidenceangles greater than 45 degrees that match the mill rates of the firstmaterial at incidence angles greater than 45 degrees.
 63. The apparatusof claim 62 in which selecting a second material from known materialscomprises selecting a second material having mill rates at incidenceangles greater than 45 degrees that are equal to or greater than themill rates of said first material at incidence angles greater than 45degrees.
 64. The apparatus of claim 61 in which selecting a secondmaterial from known materials comprises: selecting a preliminary groupof materials from known materials with mill rates at higher incidenceangles that match the mill rates of said first material at higherincidence angles; determining the electron emission coefficient of saidfirst material; determining the electron emission coefficient of eachselected preliminary material; and selecting from said preliminarygroup, an appropriate second material having the greatest relativedifference in electron emission coefficient as compared to said firstmaterial.
 65. The apparatus of claim 64 in which selecting a secondmaterial from known materials comprises selecting a second materialhaving mill rates at incidence angles greater than 45 degrees that matchthe mill rates of the first material at incidence angles greater than 45degrees.
 66. The apparatus of claim 61 in which a non-planarcross-section is desired and in which selecting a second material fromknown materials comprises selecting a second material having mill ratesat incidence angles greater than 45 degrees that do not match the millrates of the first material at incidence angles greater than 45 degrees.67. The apparatus of claim 66 in which the desired cross-sectiontopography comprises a recessed cross-section face.
 68. The apparatus ofclaim 67 in which selecting a second material from known materialscomprises selecting a second material having mill rates at incidenceangles greater than 45 degrees that are that are substantially lowerthan the mill rates of said first material at incidence angles greaterthan 45 degrees.